A Aluminum 3d printed rocket nozzle is tested by nasa

NASA recently tested a 3D-printed aluminum rocket nozzle. The project aims to develop lightweight nozzles that can withstand high temperatures and pressures.

NASA worked with Elementum 3D and RPM Innovations to build the nozzle. The nozzle was made from weldable aluminum using additive manufacturing.

The project aims to pave the way for deep space missions. The first rocket with 3D-printed components to reach space was the Terran 1 by Relativity Space. It launched from Cape Canaveral Space Force Station in Florida on March 22, 2023.

The Terran 1 rocket used an innovative copper alloy developed at NASA’s Glenn Research Center. The alloy can withstand temperatures up to 40% higher than traditional copper alloys. This leads to higher performance components and reusability.

The Terran 1 was the first test rocket made entirely from 3D-printed parts. It was 100 feet tall and 7.5 feet wide. The primary and secondary structures of the rocket were manufactured with Relativity’s Stargate 3D printer out of aluminum alloy.

The copper alloy is called GRCop-42. It’s a copper-chromium-niobium alloy that was developed by NASA. It’s designed for use in high-temperature, high-heat flux applications like liquid rocket engine combustion devices.

GRCop-42 has the following properties:

High strength
High conductivity
Excellent creep resistance
Low cycle fatigue life
Retains strength at high temperature

GRCop-42 can be additively manufactured using laser powder bed fusion or directed energy deposition technologies

NASA uses several 3D printers, including:

Zero G: A zero-gravity 3D printer that uses Fused Filament Fabrication technology to print objects in plastic.
Metal3D: The first metal 3D printer on the International Space Station.
Additive Manufacturing Facility (AMF): A multi-material 3D printer for polymers.
Olympus: A 3D-printing system designed for building on the moon and Mars.

NASA is also testing a 3D printer from Redwire that uses moon dust as raw material.

3D printing is used in the aerospace industry to manufacture aircraft components and parts. 3D printing is also used to repair aerospace and military equipment.

Here are some 3D printing types used in aerospace:

SLA: Stereolithography is used to fabricate interior components for aircraft.
SLS: Selective laser sintering is used to fabricate interior components for aircraft.
DMLS: Used to manufacture metal-based components and parts of the aircraft.
EBM: Used to manufacture metal-based components and parts of the aircraft.
SLM: Selective laser melting is the preferred metal 3D printing process for aircraft on Earth.

3D printing is also used to manufacture: